Electrical fittings with integral cover plate and method of use thereof

ABSTRACT

An electrical fitting that comprises an integral cover plate and an electrical component, such as an outlet or a switch, the combined electrical component/cover plate being secured via screws through the cover plate into a wall box. Wires are secured to power wires coming from the wall box via quick-connectors or wirenuts.

CROSS-REFERENCE TO RELATED APPLICATIONS

To the full extent permitted by law, the present United StatesNon-provisional Patent Application, is a Continuation of, United StatesNon-provisional application entitled “Electrical Fittings with IntegralCover Plate and Method of Use Thereof,” having assigned Ser. No.14/546,515, filed on Nov. 18, 2014, which claims benefit of UnitedStates Non-provisional application entitled “Electrical Fittings withIntegral Cover Plate and Method of Use Thereof,” having assigned Ser.No. 13/460,060, filed on Apr. 30, 2012, incorporated herein by referencein its entirety.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

None

PARTIES TO A JOINT RESEARCH AGREEMENT

None

REFERENCE TO A SEQUENCE LISTING

None

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The present invention relates generally to electrical fittings orfixtures, and more specifically to electrical fittings or fixtureshaving an integral cover plate.

2. Description of Related Art

During construction of buildings, both commercial and residential, it iscommon to provide an electrical wall box for receiving an electricalfitting, such as, an outlet or a switch. The electrical wall box istypically secured to the side of a vertical stud. Once the wall box isinstalled, wallboard is typically installed over the studs and anopening is cut in the wallboard in order to pass the electrical fittingthrough the wallboard. Often, the opening is cut prior to installationof the wall box and the wall box is secured to align with the opening.Electrical wiring from a power source enters the wall box via an openingtherein, wherein the electrical wiring is accessible from the front ofthe wall box.

To complete the installation of the electrical fitting, wires from thefitting are secured to corresponding wires in the wall box, such as, viawire nuts, and the fitting is secured, typically via screws that engagetubular openings (threaded or unthreaded - for self-tapping screws) inthe wall box. Subsequently, a decorative cover plate is installed overthe fitting, by securing the cover plate, such as, via screws thatengage threaded openings in the fitting.

Whenever a building is undergoing renovation, the existing wall fittingsand their cover plates are often in need of replacement or may simplyneed to be replaced to provide a different appearance. Further, it isoften necessary to replace a single, defective fitting.

In order to replace such existing fittings, once the old cover platesand fittings are removed, typically a new fitting is installed bysecuring the wires of the new fitting to their corresponding wires inthe wall box (step one), securing the fitting to the wall box (steptwo), and, subsequently, securing a new cover plate over the replacedfitting (step three). All of these steps are labor intensive, resultingin higher costs than would otherwise be incurred through a simplerapparatus and method of installation. Moreover, stock keeping units mustbe maintained for both the fittings and the cover plates, therebyincreasing record-keeping costs for inventory.

When installing an electrical fitting to a wall box, the fitting hasopenings for fasteners to engage the wall box receiving apertures. Oncethe fitting is installed, the cover plate is secured via fastenersthrough different openings, thus requiring both different locations forthe openings that receive the fasteners, but more importantly, a largernumber of openings that should be required.

Therefore, it is readily apparent that there is a need for an electricalfitting and cover plate combination that reduces the typical three stepinstallation to a wired wall box from three steps to two.

BRIEF SUMMARY OF THE INVENTION

Briefly described, in a preferred embodiment, the present inventionovercomes the above-mentioned disadvantages and meets the recognizedneed for such a device by providing an electrical fitting, such as, forexemplary purposes only and without limitation, an electrical outlet oran electrical switch, wherein the electrical fitting comprises anintegral cover plate, and wherein the composite electrical fitting/coverplate is secured via screws through the cover plate into the wall box,thereby reducing inventory for parts suppliers and labor costs forinstallation.

According to its major aspects and broadly stated, the present inventionin its preferred form is a composite electrical fitting comprising anelectrical component having an integrally-formed cover plate, theelectrical component and cover plate comprising a single unit. Thecomposite electrical fitting is dimensioned to be received by a wallbox, the wall box having apertures dimensioned to cooperatively engagefasteners. The cover plate has one or more openings therein that aredimensioned to receive fasteners. Preferably, the composite electricalfitting is removably secured to the wall box via the fasteners.

The electrical component has integral wires, each having a first end anda second end, with the first end in electrical communication with theelectrical component, and each wire of the electrical component has aquick-connect member disposed at the second end thereof. Thequick-connect member comprises a gripping member dimensioned to securean electrical conductor therewithin. The electrical conductor typicallycomprises a sheath therearound, and the quick-connect member has acutting member dimensioned to pierce the sheath.

The electrical component may comprise an electrical outlet having one ormore receptacles for receiving electrical plugs, and/or may comprise anelectrical switch. Preferably, the electrical component comprises tworeceptacles. Alternatively, the electrical component comprises fourreceptacles.

In the course of either an initial installation or for remodelling, anelectrical fitting/cover plate combination is obtained and each of itswires is secured to a corresponding wire coming out of the electricalwall box via the quick-connect member which pierces the insulatingsheath of the wire coming from the wall box. Subsequently, theelectrical fitting/cover plate combination is secured to the electricalwall box by passing one or more fasteners through the openings in thecover plate and engaging the fasteners cooperatively with receivingapertures in the wall box.

More specifically, the present invention is a composite electricalfitting having an electrical component and a cover plate that areintegrally formed together. The electrical component comprises forexemplary purposes only, an outlet or a switch which is installed in awall section.

Typically, the wall section has an opening cut therein to allow accessto electrical wall boxes from outside of the wall. The wall box istypically secured to a selected stud within the wall via a nail or ascrew. The wall box has apertures for receiving screws to retain anelectrical component therein and has an opening in the rear, sides ortop of wall box to permit power supply wiring comprising a group ofinsulated conductors to pass into the wall box. The insulated conductorscomprise conductors with insulating sheaths surrounding the conductorsto insulate them.

The cover plate of the composite electrical fitting comprisesthroughholes dimensioned to receive fasteners inserted therethrough. Theelectrical component comprises, preferably, a duplex outlet having wiresextending therefrom, such as, for exemplary purposes only, a hot wire, aneutral wire and a ground wire. The hot wire, the neutral wire and theground wire each have a first end and a second end. The duplex outletfurther comprises an upper receptacle and a lower receptacle, bothdimensioned to receive electrical plugs for lamps, appliances orsimilar. The upper receptacle and lower receptacle are connected inparallel so that a single set of wires exits the duplex outlet.

At that end of the wires from the electrical component, there arequick-connectors that have gripping members to secure a wire thereinand/or cutting members to pierce the insulation sheath of the insulatedconductors disposed therein to provide electrical communication betweenthe conductor and the electrical component. In an alternativeembodiment, the composite electrical fitting may not havequick-connectors, but, instead, is connected to power supply wirescoming from the wall box via wirenuts.

To install the composite electrical fitting, the hot wire from the mainscoming from the wall is inserted into a quick-connect member on the hotwire of the electrical component, the wall neutral wire is inserted intoa quick-connect member on the neutral wire of the electrical component,and the wall ground wire is inserted into a quick-connect member on theground wire of the electrical component. Subsequently, the compositeelectrical fitting is secured to the wall box via one or more fasteners,with the cover plate covering the wall box opening.

In an alternate embodiment, the electrical component may comprise aswitch, and, in another alternate embodiment, the electrical componentmay comprise a quad outlet with its receptacles wired in parallel.

Accordingly, a feature and advantage of the present invention is itsability to reduce labor costs for initial installation and forretrofitting of electrical fittings.

Another feature and advantage of the present invention is its ability toreduce the number of stock keeping units for inventory purposes.

Still another feature and advantage of the present invention is itsability to be quickly installed.

Yet another feature and advantage of the present invention is itsability to be utilized with a variety of electrical components.

Yet still another feature and advantage of the present invention is thatit requires only simple tools for installation.

Still yet another feature and advantage of the present invention is thatit is secured via fewer fasteners that is required by typical electricalfixtures with separate cover plates.

These and other features and advantages of the present invention willbecome more apparent to one skilled in the art from the followingdescription and claims when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The present invention will be better understood by reading the DetailedDescription of the Preferred and Selected Alternate Embodiments withreference to the accompanying drawing figures, in which like referencenumerals denote similar structure and refer to like elements throughout,and in which:

FIG. 1 is a perspective view of a wall section having an electrical wallbox installed therein;

FIG. 2A is a front exploded perspective view of an electrical fittingaccording to a preferred embodiment, shown connected and secured to anexisting electrical wall box;

FIG. 2B is a rear perspective view of an electrical fitting according tothe preferred embodiment;

FIG. 2C is a detail perspective view of a wire from an electricalfitting according to the preferred embodiment, shown with aquick-connect used to join to another wire;

FIG. 3 is a front exploded perspective view of an electrical fittingaccording to a preferred embodiment, shown connected and secured to anexisting electrical wall box;

FIG. 4 is a front perspective view of an electrical fitting according toan alternate embodiment; and

FIG. 5 is a front perspective view of an electrical fitting according toan alternate embodiment.

DETAILED DESCRIPTION OF THE PREFERRED AND SELECTED ALTERNATE EMBODIMENTSOF THE INVENTION

In describing the preferred and selected alternate embodiments of thepresent invention, as illustrated in FIGS. 1-5, specific terminology isemployed for the sake of clarity. The invention, however, is notintended to be limited to the specific terminology so selected, and itis to be understood that each specific element includes all technicalequivalents that operate in a similar manner to accomplish similarfunctions.

Referring now to FIGS. 1-3, the present invention in a preferredembodiment comprises composite electrical fitting (best shown in FIG.2A), wherein composite electrical fitting 10 comprises electricalcomponent 50 and cover plate 60, wherein electrical component 50 andcover plate 60 are integrally formed.

Turning now to FIG. 1, depicted therein is wall W, having studs Stherewithin. An opening A is preferably cut in wall W, wherein opening Ais dimensioned to allow access to interior of wall box B from outside ofwall W. Wall box W is secured to a selected stud S via fasteners as areknown in the art. Wall box B comprises apertures T for receivingfasteners, such as, for exemplary purposes only, fasteners 20 discussedhereinbelow and wall box B further comprises opening O, typically in therear of wall box B, or alternatively in a side or top of wall box B.Power supply wiring G comprises a group of insulated conductors I,wherein power supply wiring G passes through opening O in wall box B andis accessible from within wall box B (best shown in FIGS. 2C and 3).Insulated conductors I comprise conductors C and sheaths H, whereinsheaths H surround conductors C thereby insulating same.

Referring now to FIGS. 2A and 2B, cover plate 30 of composite electricalfitting 10 comprises throughholes 30, wherein throughholes 30 aredimensioned to receive fasteners 20 therethrough. Electrical component50 comprises duplex outlet 140 and wires 40, wherein wires 40 comprisehot wire 40A, neutral wire 40B and ground wire 40C. Hot wire 40Acomprises first end 70A and second end 80A, neutral wire 40B comprisesfirst end 70B and second end 80B, and ground wire 40C comprises firstend 70C and second end 80C. Duplex outlet 140 comprises upper receptacle50A and lower receptacle 50B, wherein upper receptacle 50A and lowerreceptacle 50B are dimensioned to receive an electrical plug connectedto, for exemplary purposes only, a lamp or an appliance, and whereinupper receptacle 50A and lower receptacle 50B are connected in parallel,and wherein first ends 70A, 70B and 70C are in electrical communicationwith upper receptacle 50A and lower receptacle 50B.

Turning now more particularly to FIG. 2C, composite electrical fitting10 further comprises quick-connectors 90, wherein quick-connectors 90are disposed at second ends 80A, 80B and 80C, and whereinquick-connectors 90 comprise gripping members 100 and/or cutting members110, wherein gripping members 100 are dimensioned to grip a selectedsize of wire and wherein cutting members 110 are dimensioned to cutthrough sheath H surrounding conductor C of insulated conductor I,thereby providing electrical communication between conductor C and aselected one of second ends 80A, 80B and 80C.

In another preferred embodiment as depicted in FIG. 3, compositeelectrical fitting 10 does not have quick-connectors 90 installed and,instead, connection between second ends 80A, 80B, 80C and respectivewall hot wire 41A, wall neutral wire 41B, and wall ground wire 41C ofwiring G is made via use of wirenuts 45, as is known in the art.

To install, wall hot wire 41A comprising insulated conductor I isinserted into quick-connect member disposed at second end 80A of hotwire 40A, wall neutral wire 41B comprising insulated conductor I isinserted into quick-connect member disposed at second end 80B of neutralwire 40B, and wall ground wire 41C comprising insulated conductor I isinserted into quick-connect member 90 disposed at second end 80C ofground wire 40C. Subsequently, composite electrical fitting 10 issecured to an existing wall box B (best shown in FIG. 3), whereinelectrical component 50 is dimensioned to be received within wall box B,and wherein cover plate 60 is dimensioned to cover wall box B. Fasteners20 are inserted through throughholes 30 and engage apertures T.

Referring now more specifically to FIG. 4, illustrated therein is analternate embodiment of composite electrical fitting 10, wherein thealternate embodiment of FIG. 4 is substantially equivalent in form andfunction to that of the preferred embodiment detailed and illustrated inFIGS. 1-3 except as hereinafter specifically referenced. Specifically,in the embodiment of FIG. 4, electrical component 50 comprises switch120, wherein switch 120 is substituted for duplex outlet 140, andwherein switch 120 comprises all of the components of FIGS. 2A and 2Bother than duplex outlet 140.

Referring now more specifically to FIG. 5, illustrated therein is analternate embodiment of composite electrical fitting 10, wherein thealternate embodiment of FIG. 5 is substantially equivalent in form andfunction to that of the preferred embodiment detailed and illustrated inFIGS. 1-3 except as hereinafter specifically referenced. Specifically,in the embodiment of FIG. 5, electrical component 50 comprises quadoutlet 120, wherein quad outlet 130 comprises upper receptacles 50A, 50Cand lower receptacles 50B, 50D, and wherein receptacles 50A, 50B, 50Cand 50D are wired in parallel. Other than duplex outlet 140, thealternative embodiment of FIG. 5 comprises all of the components ofFIGS. 2A and 2B.

The foregoing description and drawings comprise illustrative embodimentsof the present invention. Having thus described exemplary embodiments ofthe present invention, it should be noted by those skilled in the artthat the within disclosures are exemplary only, and that various otheralternatives, adaptations, and modifications may be made within thescope of the present invention. Merely listing or numbering the steps ofa method in a certain order does not constitute any limitation on theorder of the steps of that method. Many modifications and otherembodiments of the invention will come to mind to one skilled in the artto which this invention pertains having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Although specific terms may be employed herein, they are used in ageneric and descriptive sense only and not for purposes of limitation.Accordingly, the present invention is not limited to the specificembodiments illustrated herein, but is limited only by the followingclaims.

What is claimed is:
 1. A composite electrical fitting dimensioned to be received by a new or existing wall box having an opening, the opening having at least one receiving aperture, and with at least one power supply wiring passing therethough into the wall box, wherein said composite electrical fitting comprising: a cover plate having at least two sets of apertures, said at least two sets of apertures includes at least one throughhole and at least one component aperture; one or more electrical components affixed to said cover plate, each of said electrical components fitted therein said at least one component aperture in said cover plate; integral wires, said integral wires having a neutral component wire and at least one hot component wire, said neutral component wire having a first neutral component end and a second neutral component end, wherein said first neutral component end is in electrical communication with each of said one or more electrical components and said second neutral component end is in electrical communication with a neutral quick-connector, and wherein said at least one hot component wire having a first hot component end and a second hot component end, wherein said first hot component end is in electrical communication with at least one of said one or more electrical components and said second hot component end is in electrical communication with a hot quick-connector; an electrical component cover affixed to said cover plate, said electrical component cover fitted around said one or more electrical components; at least one fastener positioned through said at least one throughhole and dimensioned to fit the at least one receiving aperture.
 2. The composite electrical fitting of claim 1, further comprising a ground component wire having a first ground component end and a second ground component end, wherein said first ground component end is in electrical communication with each of said one or more electrical components and said second ground component end is in electrical communication with a ground quick-connector.
 3. The composite electrical fitting of claim 1, wherein said one or more electrical components includes a switch.
 4. The composite electrical fitting of claim 1, wherein said at least one component aperture includes two or more component apertures.
 5. The composite electrical fitting of claim 4, wherein said one or more electrical components includes an outlet.
 6. The composite electrical fitting of claim 4, wherein said one or more electrical components further comprises a group consisting of outlets and switches.
 7. The composite electrical fitting of claim 1, wherein said electrical component cover further comprises at least one opening for said integral wires to pass therethrough.
 8. The composite electrical fitting of claim 1, wherein said quick-connectors, where each quick-connector is for interconnecting one of said second ends of said integral wires with the corresponding power supply wiring from the wall box.
 9. The composite electrical fitting of claim 1, wherein said composite electrical fitting is removably secured to the wall box via said at least one fastener.
 10. The composite electrical fitting of claim 1, wherein said quick-connectors, where said hot quick-connector connects to a wall hot wire of the at least one power supply wiring and where said neutral quick-connector connects to a wall neutral wire of the at least one power supply wiring.
 11. The composite electrical fitting of claim 2, wherein said ground quick-connector connects to a wall ground wire of the at least one power supply wiring.
 12. The composite electrical fitting of claim 5, wherein said first hot component end is in electrical communication with each of said one or more electrical components.
 13. The composite electrical fitting of claim 1, wherein said cover includes a vent.
 14. The composite electrical fitting of claim 1, wherein said one or more electrical components affixed to said cover plate via a latch.
 15. The composite electrical fitting of claim 1, wherein said one or more electrical components affixed to said cover plate via a heat weld.
 16. The composite electrical fitting of claim 1, wherein said one or more electrical components affixed to said cover plate via an adhesive. 